Corn smut-based denim-type fabrics methods and systems

ABSTRACT

A method for manufacturing a corn smut-based denim-type fabric comprising: performing a corn smut-based denim-type thread production process by; retting a plurality of dried corn smut husks ,rinsing the plurality of retted fibers, drying the plurality of rinsed retted fibers, separating the plurality of rinsed retted fibers from the husk, and spinning the plurality of separated rinsed and retted fibers into a plurality of corn smut-based denim-type threads.

BACKGROUND

Currently, manufacturing a pair of jeans may require about 2,000 gallons of water. Jeans processing may also use harsh chemicals and unsavory labor conditions. This can create dangerous water waste. Jeans are mostly made of cotton which can be a highly water-intensive crop. Furthermore, relaxing jeans often requires repetitive washes which may lead to more water waste. Stretch jeans, blended with elastane or rayon, release plastic residue into water. Jeans processing also uses chemical coloring. Indigo and synthetic dyes may be toxic, and pollute aquatic life. Denim can be also faded with sandblasting, which creates small particles that cause respiratory illness. Pumice dust, used in stone washing, also poses a danger to employees and leftover fragments take time to remove. Common post processing bleaching agents can cause permanent respiratory and gastrointestinal damage from exposure and most facilities don't have the proper ventilation systems and protective gear for employees. Accordingly, improvements to the manufacturing of jean denim that reduce water waste and use less dangerous chemicals are desired.

SUMMARY OF THE INVENTION

In one aspect, a method for manufacturing a corn smut-based denim-type fabric comprising: performing a corn smut-based denim-type thread production process by; retting a plurality of dried corn smut husks ,rinsing the plurality of retted fibers, drying the plurality of rinsed retted fibers, separating the plurality of rinsed retted fibers from the husk, and spinning the plurality of separated rinsed and retted fibers into a plurality of corn smut-based denim-type threads.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 illustrates an example process for manufacturing corn smut-based denim-type fabrics, according to some embodiments.

FIG. 2 illustrates an example thread production process, according to some embodiments.

FIG. 3 illustrates an example process for implementing microbial dyeing on corn-smut based threads, according to some embodiments.

FIG. 4 illustrates an example process implementing biological post-processing on the biologically dyed, corn-husk based threads, according to some embodiments.

The Figures described above are a representative set and are not exhaustive with respect to embodying the invention.

DESCRIPTION

Disclosed are a system, method, and articles of manufacture for corn smut-based denim-type fabrics. The following description is presented to enable a person of ordinary skill in the art to make and use the various embodiments. Descriptions of specific devices, techniques, and applications are provided only as examples. Various modifications to the examples described herein can be readily apparent to those of ordinary skill in the art, and the general principles defined herein may be applied to other examples and applications without departing from the spirit and scope of the various embodiments.

Reference throughout this specification to ‘one embodiment,’‘an embodiment,’‘one example,’ or similar language means that a particular feature, structure, or characteristic described in connection with the embodiment is included in at least one embodiment of the present invention. Thus, appearances of the phrases ‘in one embodiment,’ ‘in an embodiment,’ and similar language throughout this specification may, but do not necessarily, all refer to the same embodiment.

Furthermore, the described features, structures, or characteristics of the invention may be combined in any suitable manner in one or more embodiments. In the following description, numerous specific details are provided, such as examples of programming, software modules, user selections, network transactions, database queries, database structures, hardware modules, hardware circuits, hardware chips, etc., to provide a thorough understanding of embodiments of the invention. One skilled in the relevant art can recognize, however, that the invention may be practiced without one or more of the specific details, or with other methods, components, materials, and so forth. In other instances, well-known structures, materials, or operations are not shown or described in detail to avoid obscuring aspects of the invention.

The schematic flow chart diagrams included herein are generally set forth as logical flow chart diagrams. As such, the depicted order and labeled steps are indicative of one embodiment of the presented method. Other steps and methods may be conceived that are equivalent in function, logic, or effect to one or more steps, or portions thereof, of the illustrated method. Additionally, the format and symbols employed are provided to explain the logical steps of the method and are understood not to limit the scope of the method. Although various arrow types and line types may be employed in the flow chart diagrams, and they are understood not to limit the scope of the corresponding method. Indeed, some arrows or other connectors may be used to indicate only the logical flow of the method. For instance, an arrow may indicate a waiting or monitoring period of unspecified duration between enumerated steps of the depicted method. Additionally, the order in which a particular method occurs may or may not strictly adhere to the order of the corresponding steps shown.

DEFINITIONS

Example definitions for some embodiments are now provided.

Acetic acid is an acidic, colorless liquid and organic compound with the chemical formula CH3COOH (e.g. also CH3CO2H, C2H4O2, or HC2H3O2).

Biostoning uses the action of enzymes to selectively modify a fabric surface. Enzymes ca be used to remove starchy and waxy residues from raw materials and to provide a uniform finish to fabrics/textiles. The use of enzymes allows the corn-based denim garment washing procedure to be carried out under mild conditions in the absence of pumice stones and harsh chemical agents.

Cellulase is any of several enzymes produced chiefly by, inter alia: fungi, bacteria, and protozoans that catalyze cellulolysis, the decomposition of cellulose and of some related polysaccharides.

Corn smut is a plant disease caused by the pathogenic fungus Ustilago maydis that causes smut on maize and teosinte. The fungus forms galls on all above-ground parts of corn species.

Denim is a sturdy warp-faced textile in which the weft passes under two or more warp threads.

Husk can be the outer shell or coating of a seed. With respect to corn/maize, the husk can refer to the leafy outer covering of an ear of corn as it grows on the plant.

EXAMPLE METHODS

Present methods generate a fabric using husks of corn infected with corn smut. Methods can weave of healthy husks and smut-diseased husks together in a functional fabric. Additional processes steps can fabric a wearable denim-type cloth. Diseased corn husks are turned into textile fibers. The lignocellulose fibers (e.g. fibers of dry plant matter, etc.) scan be separated from the husk and spinning it into a yarn. Natural dyes can be used to color the denim-type cloth. Natural dyes can be derived from non-animal sources, including, inter alia: roots, berries, bark, leaves, wood, fungi, and lichens.

FIG. 1 illustrates an example process 100 for manufacturing corn smut-based denim-type fabrics, according to some embodiments. In step 102, process 100 performs a corn smut-based denim-type thread production process.

FIG. 2 illustrates an example thread production process 200, according to some embodiments. In step 202, process 200 can implement the retting of corn smut husks. To facilitate the separation of the cellulose fibers from the husk, in a process called retting, process 200 soaks the dried corn husk in a solution of sodium hydroxide (NaOH) and piping hot water (e.g. in the range of 120 degrees Fahrenheit, etc.). The chemical solution breaks down the organic material in the husk and leaves us with fiber clumps.

In step 204, process 200 can rinse the retted fibers. For example, the fibers can then be rinsed with water. The fibers can be neutralized with 20% acetic acid (e.g. ˜20%, or a similar percentage of acetic acid and/or similar type solution (e.g. vinegar, etc.), etc.). The fibers can then be left to dry.

In step 206, once the fibers are separated from the husk, process 200 can spin them into threads (e.g. using a hand loom, etc.).

In step 208, process can iterate spinning of threads through specified mixtures. It is noted that, in some embodiments, a flax blend can be included into the threads produced by process 200.

In one example of process 200, a 1% cellulase solution can be used. These can be incubated for one hour at 55 degrees Celsius. They can then sit in the solution for 24 hours at room temperature. Cellulase powder can be added into H2O. This can be mixed (e.g. by slightly shaking the container, etc.).

Returning to process 100, in step 104, process 100 implements microbial dyeing. This can be done on corn-smut based thread. FIG. 3 illustrates an example process 300 for implementing microbial dyeing on corn-smut based threads, according to some embodiments. Process 300 can be implemented the output of process 200. In step 302, process 300 selects and obtains a range of bacteria that are natural and/or genetically engineered to create diverse colors. These colors can range from, for example, light pink to dark violet. These colors can include navy blue and can be bioluminescent. In step 304, generate/obtain said bacterial dye(s). The dye preparation process can be prepared. In step 306, the bacterial dye is used as a substitute of a traditional chemical dye, and the yarn/threads are dyed.

It is noted that bacterial dye can be used mitigate two existing problems of the traditional denim-making process: non-biodegradable chemical coloring and excessive water consumption.

Returning to process 100, in step 106, process 100 implements biological-based post-processing. FIG. 4 illustrates an example process 400 implementing biological post-processing on the biologically dyed, corn-husk based threads, according to some embodiments. In step 402, process 400 uses biostoning to soften the textile. Biostoning is method of using cellulases to thin and post process the fabric. Cellulases are a group of enzymes that breaks down plant fibers, requiring significantly less water in post-processing. In some embodiments, process 400 does not use pumice or other bleaching agents. In step 404, the post-processing enzymes are recycled to save water as samples do not need to be replaced. In step 406, small doses of enzymes can replace dozens of pounds of pumice. In some examples, industrial cellulases are almost produced from aerobic cellulolytic fungi, such as Hypocrea jecorina (T. reesei) or Humicola insolens can be used as the cellulase employed in biostoning. Although process 400 can use of acidic cellulose from Trichoderma along with proteases as well. The dyed corn smut-based denim-type yarn/threads can be used to generate corn smut-based denim-type fabrics.

CONCLUSION

Although the present embodiments have been described with reference to specific example embodiments, various modifications and changes can be made to these embodiments without departing from the broader spirit and scope of the various embodiments. Accordingly, the specification and drawings are to be regarded in an illustrative rather than a restrictive sense. 

What is claimed as new and desired to be protected by Letters Patent of the United States is:
 1. A method for manufacturing a corn smut-based denim-type fabric comprising: performing a corn smut-based denim-type thread production process by; retting a plurality of dried corn smut husks, rinsing the plurality of retted fibers, drying the plurality of rinsed retted fibers, separating the plurality of rinsed retted fibers from the husk, and spinning the plurality of separated rinsed and retted fibers into a plurality of corn smut-based denim-type threads.
 2. The method of claim 1 further comprising: iterating the spinning of plurality of corn smut-based denim-type threads with a flax blend-based thread.
 3. The method of claim 1 further comprising: microbial dyeing the plurality of corn smut-based denim-type threads.
 4. The method of claim 1, wherein the plurality of corn smut husks comprises a plurality of corn husks plant infected by a Ustilago maydis fungus.
 5. The method of claim 1, wherein the step of retting the plurality of corn smut husks comprises: soaking the plurality of dried corn husk in a solution comprising a specified sodium hydroxide (NaOH) and hot water.
 6. The method of claim 1, wherein the step of rinsing the plurality of retted fibers comprises: rinsing the plurality of retted fibers in water; and neutralizing the plurality of retted fibers in a solution of 20% acetic acid.
 7. The method of claim 1 further comprising: using a hand loom to spin the plurality of separated rinsed and retted fibers.
 8. The method of claim 1 further comprising: implementing a biological post-processing on the biologically dyed, corn-husk based denim threads.
 9. The method of claim 8, wherein the step of implementing a biological post-processing on the biologically dyed, corn-husk based denim threads further comprises: biostoning the on the biologically dyed, corn-husk based denim threads.
 10. The method of claim 9, wherein a cellulase derived from an aerobic cellulolytic fungi enzyme is used for biostoning.
 11. The method of claim 10, wherein the step of implementing a biological post-processing on the biologically dyed, corn-husk based denim threads further comprises: recycling a post-processing enzyme after the biostoning is completed. 